8th-sem-project-report-4,5,6,7 page.docx

download 8th-sem-project-report-4,5,6,7 page.docx

of 7

Transcript of 8th-sem-project-report-4,5,6,7 page.docx

  • 8/10/2019 8th-sem-project-report-4,5,6,7 page.docx

    1/7

    Development of HVOF thermally sprayed molybdenum coatings for sheet metal applications

    Departement of Mechanical Engineering.PESIT

    ABSTRACT

    The shift from conventional manufacturing to green manufacturing is quickly picking up pace in

    India. This project was undertaken on the similar lines of green manufacturing to suggest a

    substitute (molybdenum coatings) to popular but hazardous phosphate coatings. For years HVOF

    thermal spray coatings has been the most preferred choice in the field of wear and corrosion

    protection. The present study focuses on relatively new molybdenum coatings to improve the

    formability characteristics of sheet metal. Sheet metal finds a lot of application in the field of

    automotive, defense, aeronautical, and here its formability characteristics has the major role to

    play. But unfortunately this aspect has not been investigated at length by the researchers in the

    past. Hence, the present work focuses on developing Molybdenum coatings on low carbon steel

    by HVOF technique and to characterize its formability by means of Erichsen cupping test.

    Microstructural studies have been carried out. Further Vickers hardness test, three point bending

    test and salt spray corrosion tests on the specimens of uncoated mild steel, phosphate coated mild

    steel and molybdenum coated mild steel sheet with the sheet dimensions being

    (200mmx200mmx3mm). Microstructural studies indicate that the coatings developed by thermal

    spray HVOF process is dense and uniform in thickness. Molybdenum coatings possessed highest

    hardness, excellent formability in terms of cupping height depth and corrosion resistance when

    compared with phosphated and uncoated low carbon mild steel.

  • 8/10/2019 8th-sem-project-report-4,5,6,7 page.docx

    2/7

    Development of HVOF thermally sprayed molybdenum coatings for sheet metal applications

    Departement of Mechanical Engineering.PESIT

    ACKNOWLEDGEMENT

    The satisfaction and euphoria that accompany the successful completion of any task would beincomplete without the mention of the people who made it possible, whose constant guidance

    and encouragement crowned out effort with success.

    We express our deep sense of gratitude to my

    guide Dr. C.S Ramesh, Professor, P.E.S. Institute of Technology Bangalore for his untiring and

    valuable guidance with constant encouragement at every stage of this project work. We are

    grateful to Dr. K.S. Sridhar, Professor& Head of the Department of Mechanical Engineering,

    P.E.S. Institute of technology for giving me the consent to carry out the dissertation work. Wealso express my sincere gratitude to Dr. K.N. Balasubramanya Murthy, Principal & Director,

    P.E.S. Institute of technology, Bangalore for permitting to carry out the dissertation work.

    We sincerely

    thank Dr. K.T. Kashayp, Professor, Department Mechanical Engineering, P.E.S Institute of

    technology for his constant support in carrying out project work. I sincerely thank Dr. Rajesh

    Mathivanan N, Associate Professor, Department Mechanical Engineering, P.E.S Institute of

    technology for his constant support and valuable advice

    We are very grateful to all the teaching,

    non-teaching, and administrative staff of Department of Mechanical Engineering, P.E.S. Institute

    of Technology for their kind co-operation during this work. Finally, we thank to almighty, Our

    Parents, friends for their help and support throughout our course and all who have helped me

    directly and indirectly during this course of project

  • 8/10/2019 8th-sem-project-report-4,5,6,7 page.docx

    3/7

    Development of HVOF thermally sprayed molybdenum coatings for sheet metal applications

    Departement of Mechanical Engineering.PESIT

    TITLE PAGE NO.Chapter 1 Introduction 1

    Chapter 2 Literature survey 2

    Chapter 3 Highlights of project 4

    3.1 Aim of the project 4

    3.2 Need for green manufacturing 4

    3.3 Green Manufacturing 5

    3.4 Need for formability test 9

    3.4.1 formability of sheet metals 10

    3.4.2 Effect of material property on formability 10

    Chapter 4 Study of chosen specimen 11

    4.1 A brief history of metal sheet 11

    4.1.1 Ferrous materials 12

    4.1.2 Plain carbon steels 12

    4.2 Properties and application of mild steel 13

    4.2.1 Physical properties 14

    4.2.2 Chemical properties 14

    4.2.3 Application 14

    Chapter 5 Study of the chosen coating materials 16

    5.1 Study of molybdenum metal 165.2 Properties of molybdenum 17

    5.3 Application of Molybdenum 17

    5.4 Study of molybdenum Coatings 19

    5.5 Molybdenum in amorphous form 21

    5.5.1 Physical data 22

    5.5.2 Application of Molybdenum powder 22

    5.6 Phosphorus and its effect 23

    5.6.1 Health effect of Phosphorus 23

    5.6.2 Environmental effects of Phosphorus 24

    5.7 Phosphate coatings 24

    5.7.1 Advantages 25

    5.7.2 Process of phosphating 25

    5.7.3 Procedure of coating 25

    5.7.4 Hazardous impact of Phosphating 26

    Chapter 6 Study of chosen coating process-HVOF 27

    Table of Contents

  • 8/10/2019 8th-sem-project-report-4,5,6,7 page.docx

    4/7

    Development of HVOF thermally sprayed molybdenum coatings for sheet metal applications

    Departement of Mechanical Engineering.PESIT

    6.1 Benefits of the process 27

    6.2 Process details 28

    Chapter 7 Experimental Details 29

    7.1 Phosphating 29

    7.2 Molybdenum coating 31

    7.2.1 What is grit blasting? 31

    7.2.2 Application of grit blasting 31

    7.2.3Experimental procedure of Molybdenum

    Coating with HVOF thermal spray32

    7.3 Result and analysis of SEM test 37

    7.4 Erichsen cupping test 41

    7.4.1 Conduction of The Erichsen cupping est 41

    7.4.2 Principle of the test 41

    7.4.3 Conduction and procedure of The test 42

    7.4.4 Condition of testing equipment 437.4.5 Cupping test results 45

    7.5 Salt Spray corrosion test 48

    7.5.1 The Principle 49

    7.5.2 Testing equipment 49

    7.5.3 Applications 50

    7.5.4 Testing procedure and results 51

    7.6 Hardness test 53

    7.6.1 Vicker hardness test 53

    7.6.2 Hardness test results 567.7 Bending test 57

    7.7.1 What are bend allowances? 57

    7.7.2 What Is K-factor? 59

    7.7.3 Reverse engineering K-factor 60

    7.7.4 Results 62

    Chapter 8 Conclusion 64

    Chapter 9 Scope of future works 65

    Chapter10 Future works 66

  • 8/10/2019 8th-sem-project-report-4,5,6,7 page.docx

    5/7

    Development of HVOF thermally sprayed molybdenum coatings for sheet metal applications

    Departement of Mechanical Engineering.PESIT

    LIST OF FIGURES

    Figure

    No.

    Description Page No.

    3.1 Car wiper motor 5

    3.2 Green manufacturing 6

    5.1 Molybdenum metal 17

    5.2 Molybdenum coatings on several specimen 20

    5.3 Molybdenum powder 21

    6.1 HVOF thermal spray gun 27

    6.2 Process of HVOF coating 28

    7.1 Mild steel sheet [200mmX200mmX3mm] 29

    7.2 Zinc phosphate powder 30

    7.3 The process of zinc phosphating 30

    7.4 Mild steel sheet after zinc phosphate coating 31

    7.5 Mild steel sheet after grit blasting 32

    7.6 The set temperature 33

    7.7 The set level of oxygen,fuel and air 33

    7.8 HVOF gun 34

    7.9 Grit blasting in progress 34

    7.10 Grit blasting equipment 35

    7.11 Molybdenum coating in progress 35

    7.12 Mild steel sheet after Molybdenum coating 36

    7.13 Moly coated sheet on the right and phosphated on the left 36

    7.14 Moly coated under 2000X 37

    7.15 Phosphate coated under 2000X 37

    7.16 Moly coated under 800X 37

    7.17 Phosphatecoated under 800X 37

    7.18 Moly coated under 400X 38

    7.19 Phospahte coated under 400X 38

  • 8/10/2019 8th-sem-project-report-4,5,6,7 page.docx

    6/7

    Development of HVOF thermally sprayed molybdenum coatings for sheet metal applications

    Departement of Mechanical Engineering.PESIT

    LIST OF TABLES

    7.20 Moly coated under 200X 39

    7.21 Phosphate coated under 200X 39

    7.22 Moly coated under 100X 40

    7.23 Phospahte coated under 100X 40

    7.24 Schematic diagram of cupping test 42

    7.25 Arrangement of different component during the test 44

    7.26 UTM used for cupping test 44

    7.27 Top view of mild steel sheet after the cupping test 45

    7.28 Top view of phosphate coated mild steel sheet after the cupping test 46

    7.29 Top view of moly coated mild steel sheet after the cupping test 46

    7.30 Molt coating(3),having the highest cupping depth when compared to

    phospahte coated(2) and uncoated sheets

    47

    7.31 View of the samples from the rear side 48

    7.32 Salt spray corrosion tester 50

    7.33 Mild steel sheet after corrosion test 52

    7.34 Phospahate coated mild steel sheet after corrosion test 52

    7.35 Moly coated mild steel sheet after corrosion test 52

    7.36 Vickers hardness tester 54

    7.37 Schematic diagram of Vickers test 55

    7.38 Uncaoted(1),phosphate coated(2),moly coated(3) mild steel samples

    after bending test

    63

    Figure

    No.

    Description Page No.

  • 8/10/2019 8th-sem-project-report-4,5,6,7 page.docx

    7/7

    Development of HVOF thermally sprayed molybdenum coatings for sheet metal applications

    Departement of Mechanical Engineering.PESIT

    4.1 Classification of ferrous materials 12

    4.2 Physical properties of mil steel 14

    4.3 Chemical properties of mild steel 14

    4.4 Application of mild steel 15

    5.1 Properties of molybdenum 17

    5.2 Physical data of molybdenum powder 21

    7.1 Cupping test result 45

    7.2 Salt spray corrosion test results 51

    7.3 Vickers hardness test result 57

    7.4 Result of bending test with respect to k factor 63


INTEGER RULES REFERENCE SHEETges336.waynecountyschools.org/UserFiles/Servers/Server...Microsoft Word - INTEGERS 1 PAGE.docx Created Date 20140713035441Z ...

INTEGER RULES REFERENCE SHEETges336.waynecountyschools.org/UserFiles/Servers/Server...Microsoft Word - INTEGERS 1 PAGE.docx Created Date 20140713035441Z ...

Maharshi Dayanand Universitymdu.ac.in › UpFiles › UpPdfFiles › 2019 › Jun › press note... · 10th Sem 2 Sem. 4th Sem. & 6th Sem. 5 sem & sem Re-appear only Re-appear only

Maharshi Dayanand Universitymdu.ac.in › UpFiles › UpPdfFiles › 2019 › Jun › press note... · 10th Sem 2 Sem. 4th Sem. & 6th Sem. 5 sem & sem Re-appear only Re-appear only

𝑵𝑹𝑫 - Sernac · 0 5.000 10.000 15.000 20.000 25.000 1er sem. 2do sem. 1er sem. 2do sem. 1er sem. 2do sem. 1er sem. 2do sem. 1er sem. 2do sem. 1er sem. 2do sem. 1er sem. 2do

𝑵𝑹𝑫 - Sernac · 0 5.000 10.000 15.000 20.000 25.000 1er sem. 2do sem. 1er sem. 2do sem. 1er sem. 2do sem. 1er sem. 2do sem. 1er sem. 2do sem. 1er sem. 2do sem. 1er sem. 2do

final inside page 2014 Y 65 series-oneup ENDMILL CARBIDE 200 Y65.pdf · yf4-sem 2010 yf4-sem 2015 yf4-sem 2020 yf4-sem 2025 yf4-sem 2030 yf4-sem 2040 yf6-sem 2030 yf6-sem 2040 yf6-sem

final inside page 2014 Y 65 series-oneup ENDMILL CARBIDE 200 Y65.pdf · yf4-sem 2010 yf4-sem 2015 yf4-sem 2020 yf4-sem 2025 yf4-sem 2030 yf4-sem 2040 yf6-sem 2030 yf6-sem 2040 yf6-sem

Sem-1 Sem-2 Sem-3 Sem-4 - University of Calcutta · 2018-06-06 · Sem ‐1 Sem‐2 Sem ... Engineering and ... Microbes in Sustainable Agriculture and Development B3. Instrumentation

Sem-1 Sem-2 Sem-3 Sem-4 - University of Calcutta · 2018-06-06 · Sem ‐1 Sem‐2 Sem ... Engineering and ... Microbes in Sustainable Agriculture and Development B3. Instrumentation

Sem-1 Sem-2 Sem-3 Sem-4

Sem-1 Sem-2 Sem-3 Sem-4

00 - NY Claims Kits Cover Page.docx

00 - NY Claims Kits Cover Page.docx

SEM User-Guide July2018 BRC finalVersion 2A4 reshuffle SS · SEM 1 SEM 2 SEM 3 SEM 4 SEM 5 SEM 6 SEM 7 SEM 8 SEM 9 SEM 10 % How do I get access to published SEM data? How do I get

SEM User-Guide July2018 BRC finalVersion 2A4 reshuffle SS · SEM 1 SEM 2 SEM 3 SEM 4 SEM 5 SEM 6 SEM 7 SEM 8 SEM 9 SEM 10 % How do I get access to published SEM data? How do I get

heritageit.edu · B.TECH / MCA TILL DATE ANY OTHER FINANCIAL ASSISTANCE APPLIED FOR / GRANTED Sem I Sem 11 Sem I Sem 11 Sem 111 Sem IV Sem 111 Sem IV Sem V Sem VI Sem V Sem VI Sem

heritageit.edu · B.TECH / MCA TILL DATE ANY OTHER FINANCIAL ASSISTANCE APPLIED FOR / GRANTED Sem I Sem 11 Sem I Sem 11 Sem 111 Sem IV Sem 111 Sem IV Sem V Sem VI Sem V Sem VI Sem

Sem-1 Sem-2 Sem-3 Sem-4 - collegeadmission.in · Sem-1 Sem-2 Sem-3 Sem-4 Sem-5 Sem-6 Core Courses (CC) CC1 & 2 2Th+2P (2X4+2X2=12 Credits) CC1: Introduction to microbiology and microbial

Sem-1 Sem-2 Sem-3 Sem-4 - collegeadmission.in · Sem-1 Sem-2 Sem-3 Sem-4 Sem-5 Sem-6 Core Courses (CC) CC1 & 2 2Th+2P (2X4+2X2=12 Credits) CC1: Introduction to microbiology and microbial

COVER EXAMPLES: SPINE AND FRONT COVER - Boun SBE · Microsoft Word - 4.1 sample cover page.docx Author: peggy Created Date: 20150323103832Z ...

COVER EXAMPLES: SPINE AND FRONT COVER - Boun SBE · Microsoft Word - 4.1 sample cover page.docx Author: peggy Created Date: 20150323103832Z ...

Annexure- Department of Computer Science and Engineering ...nith.ac.in/wp-content/uploads/2016/10/Syllabus.pdf · Semester Sem-I Sem-II Sem-III Sem-IV Sem-V Sem-VI Sem-VII Sem-VIII

Annexure- Department of Computer Science and Engineering ...nith.ac.in/wp-content/uploads/2016/10/Syllabus.pdf · Semester Sem-I Sem-II Sem-III Sem-IV Sem-V Sem-VI Sem-VII Sem-VIII

Scanned by CamScanner › download › › New Doc 2020-06... · 2020-06-01 · Total Eight Sem. 1st Sem. 2nd Sem. 3rd Sem. 4th Sem. 5th Sem. 6th Sem. 7th Sem. 8th Sem. Session 2019

Scanned by CamScanner › download › › New Doc 2020-06... · 2020-06-01 · Total Eight Sem. 1st Sem. 2nd Sem. 3rd Sem. 4th Sem. 5th Sem. 6th Sem. 7th Sem. 8th Sem. Session 2019

Introductory Page.docx

Introductory Page.docx

18F9 (4-(3,6-bis (ethoxycarbonyl)-4,5,6,7-tetrahydrothieno ...

18F9 (4-(3,6-bis (ethoxycarbonyl)-4,5,6,7-tetrahydrothieno ...

Life Settlement Cover page - DEPARTMENT OF …insurance.ky.gov/PPC/Documents/LifeSettlementPacket...Title Microsoft Word - Life Settlement Cover page.docx Author wesley.sirles Created

Life Settlement Cover page - DEPARTMENT OF …insurance.ky.gov/PPC/Documents/LifeSettlementPacket...Title Microsoft Word - Life Settlement Cover page.docx Author wesley.sirles Created

Welcome statement, web page - St. James High Schoolstjameshs.sharpschool.net/UserFiles/Servers/Server... · Title: Microsoft Word - Welcome statement, web page.docx Author: Michelle

Welcome statement, web page - St. James High Schoolstjameshs.sharpschool.net/UserFiles/Servers/Server... · Title: Microsoft Word - Welcome statement, web page.docx Author: Michelle

Chapter 4,5,6,7

Chapter 4,5,6,7

Question 4,5,6,7

Question 4,5,6,7

Conseil en data stratégie - Mémorandum...Sem. 1 Sem. 2 Sem. 3 Sem. 4 Sem. 5 Sem. 6 Sem. 7 Sem. 8 Sem. 9 Sem. 10 Sem. 11 Sem. 12 Sem. 13 Sem. 14 Sem. 15 Sem. 16 Sem. 17 Sem. 18 Sem.

Conseil en data stratégie - Mémorandum...Sem. 1 Sem. 2 Sem. 3 Sem. 4 Sem. 5 Sem. 6 Sem. 7 Sem. 8 Sem. 9 Sem. 10 Sem. 11 Sem. 12 Sem. 13 Sem. 14 Sem. 15 Sem. 16 Sem. 17 Sem. 18 Sem.